ELECTRIC VEHICLE COMPONENTS FOR 1000 KM DAILY TRIPS
EVC1000, which brought together 10 partners from across Europe and was coordinated by AVL List GmbH in Austria, was set up to focus on optimising EVs with this innovative in-wheel drivetrain layout. In particular, the project looked at brake and suspension control, together with in-wheel drivetrain, to achieve better vehicle dynamics. The objective was to develop new EV components that could deliver significant advantages in terms of energy efficiency – and thus vehicle range – and target other areas where user acceptance is an issue, such as vehicle stability. These solutions would then be showcased in pilot vehicles. The project began by creating a series of simulation models, to support design exploration and early validation of new components. These components were then designed and manufactured, including a dual inverter for more efficient control of several e-motors in parallel, as well as in-wheel motors for higher energy efficiency. “We also designed new chassis components, such as brake-by-wire systems and electro-hydraulic suspension with energy harvesting capabilities to provide a greater degree of freedom for advanced control strategies,” says Armengaud. “We also developed a highly efficient electro-hydraulic suspension system using X-by-Wire technology to enhance vehicle dynamics behaviour without compromising comfort.” These innovations will now be integrated into two vehicle demonstrators, to showcase the potential benefits of these solutions for different market segments. “Long-distance daily trips will allow us not only to assess energy efficiency, but also to consider how we can further enhance the customer experience,” adds Armengaud.
The project team has been successful in prototyping and evaluating a number of new components, some of which have since been patented. This will open the door to the eventual mass production of highly efficient EVs, and boost Europe’s competitiveness in this important field. As a contribution towards EV manufacturing and smarter, greener transport, EVC1000 has developed innovative components which are now on the path to industrialisation, and are expected to reach the market around 2024-2025. EVC1000 has further supported the creation of follow-up programmes including training and expert exchange, in order to create an innovation ecosystem to push cutting-edge EV technology in Europe.
participants
countries
ELECTRIC VEHICLE COMPONENTS FOR 1000 KM DAILY TRIPS
EVC1000, which brought together 10 partners from across Europe and was coordinated by AVL List GmbH in Austria, was set up to focus on optimising EVs with this innovative in-wheel drivetrain layout. In particular, the project looked at brake and suspension control, together with in-wheel drivetrain, to achieve better vehicle dynamics. The objective was to develop new EV components that could deliver significant advantages in terms of energy efficiency – and thus vehicle range – and target other areas where user acceptance is an issue, such as vehicle stability. These solutions would then be showcased in pilot vehicles. The project began by creating a series of simulation models, to support design exploration and early validation of new components. These components were then designed and manufactured, including a dual inverter for more efficient control of several e-motors in parallel, as well as in-wheel motors for higher energy efficiency. “We also designed new chassis components, such as brake-by-wire systems and electro-hydraulic suspension with energy harvesting capabilities to provide a greater degree of freedom for advanced control strategies,” says Armengaud. “We also developed a highly efficient electro-hydraulic suspension system using X-by-Wire technology to enhance vehicle dynamics behaviour without compromising comfort.” These innovations will now be integrated into two vehicle demonstrators, to showcase the potential benefits of these solutions for different market segments. “Long-distance daily trips will allow us not only to assess energy efficiency, but also to consider how we can further enhance the customer experience,” adds Armengaud.
The project team has been successful in prototyping and evaluating a number of new components, some of which have since been patented. This will open the door to the eventual mass production of highly efficient EVs, and boost Europe’s competitiveness in this important field. As a contribution towards EV manufacturing and smarter, greener transport, EVC1000 has developed innovative components which are now on the path to industrialisation, and are expected to reach the market around 2024-2025. EVC1000 has further supported the creation of follow-up programmes including training and expert exchange, in order to create an innovation ecosystem to push cutting-edge EV technology in Europe.
ADVANCED ARCHITECTURES CHASSIS/TRACTION CONCEPT FOR FUTURE ELECTRIC VEHICLES
Electric vehicles (EVs) are becoming increasingly important in the global effort to achieve climate neutrality. Reducing the number of fossil fuel-powered vehicles on the road – and improving EV efficiencies – can help to lower carbon emissions. What’s more, affordable pricing, along with technological breakthroughs, have made EVs an increasingly attractive and viable option for many consumers.
Nonetheless, the widespread adoption of EVs has been hindered by consumer hesitancy, as well as various technological challenges. These technical issues have often been linked to vehicle performance, motion dynamics and braking strategy. The ACHILES project was developed to address these challenges – and make EVs ever more market viable. “The ACHILES project focused on enhancing an existing vehicle, the Audi Q2, by defining the architecture and control strategy for different subsystems,” explains project coordinator Omar Hegazy, a professor at the Vrije Universiteit Brussel (VUB) in Belgium. “These subsystems included the brakes, chassis, battery and powertrain, with newly developed e-motors.”
The project team developed and prototyped innovative new components for each of these subsystems. These innovations were then integrated, and tested on an ACHILES vehicle. Important results were achieved in improving all four subsystems. “Each of these technological breakthroughs is a paradigm shift on its own, but together, they can significantly reduce the weight, system complexity and cost of an EV,” says Hegazy. “We were also able to show how they can increase reliability and user comfort, as well as safety and security.” The first innovation is a new torque vectoring algorithm that significantly improves vehicle dynamics. Overall stability was increased by more than 10 % through better steering. “The second innovation is a new wheel concept design equipped with full by-wire braking,” explains Hegazy. “This includes a new friction brake concept.” Tests showed that brake particle emissions could be reduced by at least 50 % by using the aluminium metal matrix composite disc installed in the ACHILES vehicle. The aluminium friction brakes also resulted in an overall weight reduction of around 19 kg. “The third innovation is an out-of-phase control, which intentionally dissipates excess braking energy in case of fully charged batteries,” adds Hegazy. “This also helps to reduce the weight of the brake system. The newly developed e-motor also enables high heat dissipation.” Finally, the fourth innovation is a centralised computer platform that hosts e-drive functionalities. This reduces the number of electronic control units and networks, and meets all necessary safety and security requirements. “This can support centralised domain controllers required to implement high automation and autonomy concepts, a key requirement for smart mobility,” notes Hegazy. “This can reduce the weight of the control system by up to 20 %.”
Hegazy and his team hope that the integration of all four ACHILES concepts into an EV will eventually help to reduce the total cost of ownership, increase the driving range and improve user acceptance and market uptake. “Moving forward, we would like to see all four technological breakthroughs further refined and optimised for mass production,” he concludes. “And second, we hope that the ACHILES project can inspire and guide future research and development efforts aimed at improving the performance, efficiency and safety of EVs.”
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FUNCTIONALLY INTEGRATED E-AXLE READY FOR MASS MARKET THIRD GENERATION ELECTRIC VEHICLES
FITGEN aimed to develop a functionally integrated e-axle ready for implementation in third generation electric vehicles. It was delivered at TRL and MRL 7 in all its components and demonstrated on an electric vehicle platform designed for the European market (A-segment reference platform). The e-axle was composed of a latest generation Buried-Permanent-Magnet Synchronous Machine, driven by a SiC-inverter and coupled with a high-speed transmission. It was complemented by a DC/DC-converter for high voltage operation of the motor in traction and for enabling super-fast charging of the 40 kWh battery (120 kW-peak) plus an integrated AC/DC on-board charger. The e-axle also included a breakthrough cooling system which combined the water motor/inverter circuit with transmission oil.
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FUNCTIONALLY INTEGRATED E-AXLE READY FOR MASS MARKET THIRD GENERATION ELECTRIC VEHICLES
FITGEN aimed to develop a functionally integrated e-axle ready for implementation in third generation electric vehicles. It was delivered at TRL and MRL 7 in all its components and demonstrated on an electric vehicle platform designed for the European market (A-segment reference platform). The e-axle was composed of a latest generation Buried-Permanent-Magnet Synchronous Machine, driven by a SiC-inverter and coupled with a high-speed transmission. It was complemented by a DC/DC-converter for high voltage operation of the motor in traction and for enabling super-fast charging of the 40 kWh battery (120 kW-peak) plus an integrated AC/DC on-board charger. The e-axle also included a breakthrough cooling system which combined the water motor/inverter circuit with transmission oil.
TOWARDS A FAST-UPTAKE OF MEDIUM/LOW-VOLTAGE ELECTRIC POWER TRAINS
Increased urban mobility needs, in combination with the demand for sustainable practices, highlight the necessity for more safe and reliable applications of electric vehicle architecture. The EU funded TELL project includes manufacturers of the currently most efficient European equipment for low and medium voltage applications, academia and an SME specialised in urban electric vehicles. The team developed optimised solutions targeted at small to medium segment electric cars, hybrid electric cars with a low voltage add-on electric propulsion system and the lightweight urban mobility sector. “For example, new knowledge will be implemented in production processes based on customer needs, educational processes and further development in follow-up projects, such as the Multi-Moby project,” notes project manager Irene Karitnig.
Made with a breakthrough technology based on silicon MOSFETs that can be exploited in all automotive segments, the novel gallium nitride high electron mobility transistor and Si MOSFET-based inverters are specifically designed for urban driving cycles. The average efficiency >96 % achieved in the 0-40 km/h speed range is remarkable. The inverter acts as the state of the art field-oriented control algorithm for electric motors with permanent magnets. It’s been optimised more by improving the motor flux model and field weakening operations. This has been possible only by using the new position sensor with high precision on the position measurement and improving the angle tracking algorithm. Accurate measurements made on machine prototypes have permitted fine tuning of control variables and optimisation of efficiency and dynamics below base speed and in field weakening areas. Moreover, a final power density of 19.3 kVA/l has been achieved thanks to the significant reduction of power losses and the increase of breakdown current.
A special focus was given to cost reduction through design and manufacturing, applying Industry 4.0 concepts in the production of both the electric powertrains and the full vehicle. Within the microfactory, the vehicles were manufactured in full steel and met the most stringent crash tests so that they could be classified as M1, vehicles used as people carriers, and N1, or goods carriers up to 3.5 tonnes. Regarding the powertrain, there is no need for external filtering in the power circuit and in the logic to get electromagnetic compatibility standards compliance. Moreover, thanks to the very high efficiency at a low voltage of the customised inverter and motor, expensive and bulky forced-air cooled devices or circuits and devices of liquid cooling are not required. With the integration of the new powertrain into the electric vehicle chassis, a high thermalisation of the battery pack and reduced range difference at outdoor temperature excursions has been made available. Moreover, the higher efficiency of the propulsion units is an enabler for the increased driving range and longer journeys with fewer stops for charging, which positively impacts urban mobility.
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CONNECTED ELECTRIC VEHICLE OPTIMIZED FOR LIFE, VALUE, EFFICIENCY AND RANGE
Electric cars (EVs) are increasingly considered by consumers as viable alternatives to fossil fuel-powered vehicles. This has long been seen as a key element in Europe’s transition towards greener forms of mobility. To fully achieve market acceptance however, some important challenges still need to be overcome. Many consumers remain wary about the range of electric vehicles – especially EVs with smaller batteries – as well as charging times, the availability of charging stations, and overall purchasing and running costs.
The EU-supported CEVOLVER project sought to tackle these issues by taking a holistic, user-centric approach to EVs. “We not only wanted to optimise the vehicle itself, but also take account of the whole environment,” explains CEVOLVER project coordinator Christof Schernus from FEV Europe in Germany. In practice, this means not only providing drivers with information on charging station locations, but also advice on how to operate their car more efficiently. “The biggest factor in EV energy usage remains the user,” says Schernus. “It is easy to double energy usage if you’re not a smooth driver. I think this knowledge – that your driving habits can significantly influence your range – is a mind-changer.” The EV prototypes used in the project feature a partially cloud-based algorithm for eco-routing, eco-charging and eco-driving. It evaluates high-resolution 3D maps, including road gradients and information about charging stations. Based on this, a faster-than-real-time model of the vehicle calculates where energy can be recuperated, and where it can be saved. This cloud service, says Schernus, helps drivers to plan their charging stops more strategically. It enables EVs with small batteries to go on long travels with minimal additional charging time. In-situ traffic information, from front camera and/or radar for example, is included in the advice the driver gets about target speed profiles and other detailed route recommendations, to minimise the energy used for driving.
The CEVOLVER consortium, which included two vehicle manufacturers, not only looked at improving the driver experience. Technological innovations to achieve better energy performance were also investigated. “Thermal management is critically important to energy efficiency,” says Schernus. “We investigated the possibility of heat storage and heat pumps, as well as utilising waste heat of batteries and electronics to warm the car while at the same time minimising the energy used to drive the heat-pumps.” The CEVOLVER team found that radiative heating panels, as well as heated seats, surfaces and steering wheels, could be far more efficient than conventional heating systems. The team also worked on preconditioning the battery to achieve fast charging. They found that controlling the battery temperature, e.g. between 25 and 35 degrees, meant that the battery could be charged much faster.
Through EV simulations and prototype demonstrations, the project succeeded in showing how huge operational efficiencies can be achieved. The key, believes Schernus, was integrating technical innovations with improving the user experience. “We want to tackle users’ concerns about EVs, so they can trust the range of vehicles, even if they have smaller batteries,” he says. “This is important, as smaller battery make vehicles lighter and more resource efficient. And of course, cheaper.” The consortium plans to apply for a follow-up project, to work further on user-centric vehicles with efficient thermal management. The hope is that these state-of-the-art innovations eventually become standard, boosting the reputation of EVs as efficient, reliable and cost-effective vehicles of the future.
participants
countries
CONNECTED ELECTRIC VEHICLE OPTIMIZED FOR LIFE, VALUE, EFFICIENCY AND RANGE
Electric cars (EVs) are increasingly considered by consumers as viable alternatives to fossil fuel-powered vehicles. This has long been seen as a key element in Europe’s transition towards greener forms of mobility. To fully achieve market acceptance however, some important challenges still need to be overcome. Many consumers remain wary about the range of electric vehicles – especially EVs with smaller batteries – as well as charging times, the availability of charging stations, and overall purchasing and running costs.
The EU-supported CEVOLVER project sought to tackle these issues by taking a holistic, user-centric approach to EVs. “We not only wanted to optimise the vehicle itself, but also take account of the whole environment,” explains CEVOLVER project coordinator Christof Schernus from FEV Europe in Germany. In practice, this means not only providing drivers with information on charging station locations, but also advice on how to operate their car more efficiently. “The biggest factor in EV energy usage remains the user,” says Schernus. “It is easy to double energy usage if you’re not a smooth driver. I think this knowledge – that your driving habits can significantly influence your range – is a mind-changer.” The EV prototypes used in the project feature a partially cloud-based algorithm for eco-routing, eco-charging and eco-driving. It evaluates high-resolution 3D maps, including road gradients and information about charging stations. Based on this, a faster-than-real-time model of the vehicle calculates where energy can be recuperated, and where it can be saved. This cloud service, says Schernus, helps drivers to plan their charging stops more strategically. It enables EVs with small batteries to go on long travels with minimal additional charging time. In-situ traffic information, from front camera and/or radar for example, is included in the advice the driver gets about target speed profiles and other detailed route recommendations, to minimise the energy used for driving.
The CEVOLVER consortium, which included two vehicle manufacturers, not only looked at improving the driver experience. Technological innovations to achieve better energy performance were also investigated. “Thermal management is critically important to energy efficiency,” says Schernus. “We investigated the possibility of heat storage and heat pumps, as well as utilising waste heat of batteries and electronics to warm the car while at the same time minimising the energy used to drive the heat-pumps.” The CEVOLVER team found that radiative heating panels, as well as heated seats, surfaces and steering wheels, could be far more efficient than conventional heating systems. The team also worked on preconditioning the battery to achieve fast charging. They found that controlling the battery temperature, e.g. between 25 and 35 degrees, meant that the battery could be charged much faster.
Through EV simulations and prototype demonstrations, the project succeeded in showing how huge operational efficiencies can be achieved. The key, believes Schernus, was integrating technical innovations with improving the user experience. “We want to tackle users’ concerns about EVs, so they can trust the range of vehicles, even if they have smaller batteries,” he says. “This is important, as smaller battery make vehicles lighter and more resource efficient. And of course, cheaper.” The consortium plans to apply for a follow-up project, to work further on user-centric vehicles with efficient thermal management. The hope is that these state-of-the-art innovations eventually become standard, boosting the reputation of EVs as efficient, reliable and cost-effective vehicles of the future.
INTEGRATED COMPONENTS, SYSTEMS AND ARCHITECTURES FOR EFFICIENT ADAPTION AND CONVERSION OF COMMERCIAL VEHICLE PLATFORMS TO 3RD GENERATION BATTERY ELECTRIC VEHICLES FOR FUTURE CO2-FREE CITY LOGISTICS
The ultimate goal of sys2WHEEL was to develop sustainable city logistics and improve mobility, accessibility, and quality of life of European citizens by taking a transdisciplinary approach. Both, in-wheel and e-axle solutions have a high potential regarding fully electric commercial vehicles for future city logistics since they provide numerous advantages and benefits, such as the increase of driving range with the same battery or keeping same range with smaller batteries. Also, a reduction of the number of components and complexity of the supply chain, compact packaging of powertrain components enabling more space for driver and freight and reduction of the vehicle weight and thus CO2 emissions. In addition, maintenance costs, energy costs and development costs can be reduced and thus the vehicle price.
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SELF-SUSTAINED AND SMART BATTERY THERMAL MANAGEMENT SOLUTION FOR BATTERY ELECTRIC VEHICLES
Innovative battery system for fast-charging electric vehicles
The electrification of the transport sector will drastically reduce fossil fuel dependency and greenhouse gas emissions in the EU. The automotive industry plans considerable investments in building electric charging infrastructure including ultra-fast charging infrastructure for electric vehicles (EVs). However, current EVs cannot accept this high charge rate. The EU-funded SELFIE project will develop and demonstrate an innovative self-sustained compact battery system to enable fast charging, significantly reduce costs and eliminate range anxiety compared to other propulsion technologies. The system consists of a Smart modular battery pack with excellent internal thermal conductivity properties, a refrigerant cooling system and thermal storage system to absorb excess heat due to fast charging, and an advanced battery thermal management system to prevent overheating.
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SELF-SUSTAINED AND SMART BATTERY THERMAL MANAGEMENT SOLUTION FOR BATTERY ELECTRIC VEHICLES
Innovative battery system for fast-charging electric vehicles
The electrification of the transport sector will drastically reduce fossil fuel dependency and greenhouse gas emissions in the EU. The automotive industry plans considerable investments in building electric charging infrastructure including ultra-fast charging infrastructure for electric vehicles (EVs). However, current EVs cannot accept this high charge rate. The EU-funded SELFIE project will develop and demonstrate an innovative self-sustained compact battery system to enable fast charging, significantly reduce costs and eliminate range anxiety compared to other propulsion technologies. The system consists of a Smart modular battery pack with excellent internal thermal conductivity properties, a refrigerant cooling system and thermal storage system to absorb excess heat due to fast charging, and an advanced battery thermal management system to prevent overheating.
SAFE, SECURE, HIGH PERFORMING MULTI-PASSENGER AND MULTI-COMMERCIAL USES AFFORDABLE EVS
On the road to electric and multi-purpose vehicles
Even though sales of electric vehicles and hybrids account for less than 2 % of new registrations in Europe, the uptake is increasing. And the future of mobility is on the path towards efficient, electric and multi-purpose vehicles. With this in mind, the EU-funded Multi-Moby project is designing a fleet of multi-passenger and multi-purpose commercial vans. With enhanced safety features, these vehicles are fitted with sensing, scanning and night vision to enhance autonomous capabilities. They also feature a robust battery pack based on hybrid cells. The vans have an on-board charger and a standardised low-cost charging system. By advancing the development of such technology, the project is driving the market towards safe and affordable electric vehicles.
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The research leading to these results have received funding from European Union’s Horizon Europe research and innovation programme H2020 and Horizon Europe.
Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European Climate, Infrastructure and Environment Executive Agency (CINEA). Neither the European Union nor the funding authority can be held responsible for them.